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AOI - Algorithms or Comparators

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AOI - Algorithms or Comparators | 2 February, 2009

Hi All,

I am looking for some independent views and reasoning as to whether Algorithm or comparison based AOI equipment are better.

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AOI - Algorithms or Comparators | 2 February, 2009

Algorithms, Schmalgorithums. They're ALL Comparators. It's just that some compare images, while others compare interpretations of images. (Algorithms)

Okay...let's see what can of worms I just opened....

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AOI - Algorithms or Comparators | 2 February, 2009


Each has their place.

Rules based systems (algorithm) are harder to program and I have seen post on here with people saying there is no real difference in defect detection.

Image based systems are much easier and intutitive to program.

If you are doing 1 million cell phones and you know the product wont change then the Rules based may be for you. If you are doing lower volume higher mix then I think you will find that Image based system is probably a better fit.

Best way to determine is pick a couple of each and ask for a local demo. Bring in the requested cad and 1 good board and 1 board with defects. Have the companies program and then run both boards.

This will give you an idea of how it will fit your paticular need.

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AOI - Algorithms or Comparators | 2 February, 2009

I have programmed one of each. The rules-based machine is about 6 years older than the model-based system, so It's probably not a fair comparison, but I prefer the model-based system by far. The model-based machine gives you a lot more flexibility and is easier to program. I programmed the rules-based machine for 5 years and have only been programming the model based machine for 1 year and I have a far greater understanding of the programming of this machine.

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AOI - Algorithms or Comparators | 6 February, 2009


Just to let you know. There is a big time rumor of another rules based system manufacture getting out of the business. I haven't been able to confirm it yet.

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AOI - Algorithms or Comparators | 9 February, 2009

The manufacturer of the rules based machine I mentioned in the post above has recently gotten out of the populated PCB side of the industry.

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AOI - Algorithms or Comparators | 9 February, 2009

Which companies are you talking about? There are now 2 that have left the industry... Orbotec announced a couple of months ago and Agilent was announced today on

With that said, We have been using the Yestech AOI systems for a while now and they work well for us, just to throw a name out there. The operation of the system is very user friendly for us and we typically get programming done quickly, about 45 minutes per side.

Good Luck!

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AOI - Algorithms or Comparators | 9 February, 2009

I was talking about Orbotech.

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AOI - Algorithms or Comparators | 9 February, 2009

Viscom is still there if in case you want to try the algorithms, we are already using them for almost 3 years now and the inspection stability and detection consistency are excellent.

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AOI - Algorithms or Comparators | 15 February, 2009

Hello Muarty,

This is the age old question on AOI. Fortunately, the answer hasn't changed much over the years. It really depends on your business...period. A high-mix low-to-mid volume manufacturer, will need to concentrate on equipment that may be progammed very easily, with very quick debug time from assembly to assembly. These attributes are typical of comparison based systems.

Higher volume manufacturers, we are talking tens of thousands of assemblies per production run, may opt for algorithm based systems. These systems are inherently more accurate than comparison based systems, but they are difficult to program and require more technical expertise at the helm.

We are a low volume high mix manufacturer. When we did our equipment evaluation, we looked at some of the higher end algorithm based machines, but determined that we simply did not have the time or resources to program these systems for our typical batch sizes. Our consultant steered us toward comparison based systems. In doing our research, we found that there were really only two vendors that were suitable for hig-mix low-to-mid volulme application: Yestech and Mirtec. We brought both systems in for evaluation.

We found that the Yestech programmed very easily, but the debug process took longer than expected, and there were several defects that were not caught right up front. This was alarming. We also ran the same boards through the machine several times and kept getting inconsistent results. The biggest advantage with Yestech was the price. They are by far the most inexpensive machine out there, but the performance was not the best.

The Mirtec machine also programmed very easily. My team and I thought that the Mirtec machine, however, was more simple to operate especially when reviewing defects. The debug time was also much faster and the machine caught every one of our defects on the first pass, as well as a cracked component which my team was not aware of. Lastly, when we ran the same boards through the machine, we got consistent inspection results as advertised. Mirtec is more expensive, but we felt that it was well worth the money based on the performance of the equipment.

Needles to say, we selected Mirtec. We now have six machines and our production quality has improved dramatically. The standard SPC software package has been a great tool in helping us resolve many of our process issues.

Hope this helps,


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